Encapsulated nickel photoreceptor substrate

Abstract

An electroforming process and apparatus for creating a nickel or like substrate encapsulated by another material to prevent wear to the nickel substrate. The encapsulation of the nickel substrate requires encapsulation of the inner and outer diameter of the nickel substrate. The encapsulating material must adhere to the nickel substrate. Encapsulation of the nickel substrate prevents exposure of the nickel and thus avoids the hazardous nickel dust particles that can occur when the nickel is exposed.

Claims

1. A method for fabricating an electroform on a mandrel, comprising:

applying a layer of a nickel material to a surface of the mandrel to create an electroform;

separating the layer of the nickel material forming the electroform from the mandrel surface; and

encapsulating the nickel material on an inside diameter and an outside diameter of the electroform with another material to prevent wear of said nickel material creating a photoreceptor belt.

2. A method as recited in claim 1, wherein the applying step comprises plating the surface of the mandrel with the layer of the nickel material having a thickness ranging from about 12 microns to about 250 microns forming a surface electroform.

3. A method as recited in claim 2, wherein the separating step comprises:

parting the nickel material of the electroform from the mandrel surface using hysterisis to maintain the mandrel surface; and

removing the nickel material of the electroform, along a longitudinal axis of the mandrel surface, to separate the mandrel surface from the nickel material of the electroform.

4. A method as recited in claim 3, wherein the encapsulating step comprises adhering the other material to the nickel material during plating of the nickel material with the second material, the other material having a thickness ranging from about 25 microns to about 70 microns.

5. A method as recited in claim 4, wherein the other material is chosen from a group of materials consisting of cobalt, brass, tin, zirconium and titanium.